Analytical Technology Q46P User manual

Model Q46P

pH Monitor

Home Office European Office

Analytical Technology, Inc. ATI (UK) Limited

6 Iron Bridge Drive Unit 1 & 2 Gatehead Business Park

Collegeville, PA 19426 Delph New Road, Delph

Saddleworth OL3 5DE

Ph:(800) 959-0299 Ph: 0800-018-4020

(610) 917-0991 + 44 (0) 1457-873-318

Fax: (610) 917-0992 Fax: + 44 (0) 1457-874-468

Email: sales@analyticaltechnology.com Email:sales@atiuk.com

PRODUCT WARRANTY

Analytical Technology, Inc. (Manufacturer) warrants to the Customer that if any part(s)

of the Manufacturer's products proves to be defective in materials or workmanship

within the earlier of 18 months of the date of shipment or 12 months of the date of start-

up, such defective parts will be repaired or replaced free of charge. Inspection and

repairs to products thought to be defective within the warranty period will be completed

at the Manufacturer's facilities in Collegeville, PA. Products on which warranty repairs

are required shall be shipped freight prepaid to the Manufacturer. The product(s) will be

returned freight prepaid and allowed if it is determined by the manufacturer that the

part(s) failed due to defective materials or workmanship.

This warranty does not cover consumable items, batteries, or wear items subject to

periodic replacement including lamps and fuses.

Gas sensors, except oxygen sensors, are covered by this warranty, but are subject to

inspection for evidence of extended exposure to excessive gas concentrations. Should

inspection indicate that sensors have been expended rather than failed prematurely, the

warranty shall not apply.

The Manufacturer assumes no liability for consequential damages of any kind, and the

buyer by acceptance of this equipment will assume all liability for the consequences of

its use or misuse by the Customer, his employees, or others. A defect within the

meaning of this warranty is any part of any piece of a Manufacturer's product which

shall, when such part is capable of being renewed, repaired, or replaced, operate to

condemn such piece of equipment.

This warranty is in lieu of all other warranties (including without limiting the generality of

the foregoing warranties of merchantability and fitness for a particular purpose),

guarantees, obligations or liabilities expressed or implied by the Manufacturer or its

representatives and by statute or rule of law.

This warranty is void if the Manufacturer's product(s) has been subject to misuse or

abuse, or has not been operated or stored in accordance with instructions, or if the

serial number has been removed.

Analytical Technology, Inc. makes no other warranty expressed or implied except as

stated above.

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Table of Contents

PART 1 - INTRODUCTION .................................. 4

1.1 General ............................................ 4

1.2 Features .......................................... 5

1.3 Q46P System Specifications ............ 6

1.4 Q46P Performance Specifications

(Common to all variations) ........................ 7

1.5 General – Q25P pH Sensor ............. 8

1.6 Sensor Features .............................. 8

1.7 Q25P Sensor Specifications ............ 9

PART 2 – ANALYZER MOUNTING ................... 11

2.1 General .......................................... 11

2.2 Wall or Pipe Mount ......................... 12

2.3 Panel Mounting .............................. 14

PART 3 – SENSOR/FLOWCELL MOUNTING .. 15

3.1 General .......................................... 15

3.2 Flow Tee Mounting ........................ 16

3.3 Union Mounting .............................. 17

3.4 Submersion Mounting .................... 18

3.5 Insertion Mounting ......................... 19

3.6 Conventional pH Sensors .............. 21

3.61 Sealed Flowcell .............................. 22

3.62 Flow Tee Adapter ........................... 23

3.7 Lock-n-Load System ...................... 24

PART 4 – ELECTRICAL INSTALLATION ......... 25

4.1 General .......................................... 25

4.2 Power Connection .......................... 26

4.3 Relay Connection ........................... 28

4.4 Optional Output or Relay

Connections ........................................... 29

4.5 Sensor Wiring ................................ 30

4.6 Direct Sensor Connection .............. 33

4.7 Junction Box Connection ............... 34

4.8 Combination Electrode

Connection ............................................. 35

4.9 External Preamplifier ...................... 37

PART 5 – CONFIGURATION ............................. 38

5.1 User Interface ................................. 38

5.11 Keys ............................................... 39

5.12 Display ........................................... 39

5.2 Software ......................................... 41

5.21 Software Navigation ...................... 41

5.22 Measure Menu [MEASURE] ........... 44

5.23 Calibration Menu [CAL] .................. 45

5.24 Configuration Menu [CONFIG] ....... 46

5.25 Control Menu [CONTROL] ............. 52

5.26 Diagnostics Menu [DIAG] .............. 59

PART 6 – CALIBRATION .................................. 64

6.1 Overview and Methods ................... 64

6.11 Sensor Slope .................................. 64

6.12 Sensor Offset ................................. 65

6.13 2-Point Calibration Explained ......... 65

6.14 1-Point Calibration Explained ......... 65

6.2 Performing a 2-Point Calibration ..... 66

6.3 Performing a 1-Point Calibration ..... 67

6.4 Temperature Calibration ................. 69

PART 7 – PID CONTROLLER DETAILS ........... 70

7.1 PID Description .............................. 70

7.2 PID Algorithm ................................. 70

7.3 Classical PID Tuning ...................... 72

7.4 Manual PID Override Control ......... 73

7.5 Common PID Pitfalls ...................... 73

PART 8 – MAINTENANCE AND

TROUBLESHOOTING ....................................... 75

8.1 System Checks .............................. 75

8.2 Instrument Checks ......................... 75

8.3 Display Messages .......................... 76

8.4 Cleaning the Sensor ....................... 80

8.5 Replacing the Saltbridge and

Reference Buffer Solution ....................... 81

8.6 Troubleshooting ............................. 82

SPARE PARTS .................................................. 84

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Table of Figures

FIGURE 1 – Q46 ENCLOSURE DIMENSIONS .................................................................................. 11

FIGURE 2 - WALL OR PIPE MOUNTING BRACKET ........................................................................... 12

FIGURE 3 - WALL MOUNTING DIAGRAM ........................................................................................ 13

FIGURE 4 - PIPE MOUNTING DIAGRAM .......................................................................................... 13

FIGURE 5 - 115/230 VAC PANEL MOUNT & CUT-OUT ................................................................... 14

FIGURE 6 - Q25 SENSOR TYPES .................................................................................................. 15

FIGURE 7 - FLOW THROUGH TEE MOUNT ..................................................................................... 16

FIGURE 8 - 1.5" UNION MOUNT .................................................................................................... 17

FIGURE 9 - SENSOR SUBMERSION MOUNT ................................................................................... 18

FIGURE 10 - S.S. SENSOR INSERTION MOUNT .............................................................................. 19

FIGURE 11 - CPVC SENSOR INSERTION MOUNT ........................................................................... 20

FIGURE 12 - (63-0013) COMBINATION PH SENSOR, FLOW TYPE .................................................... 21

FIGURE 13 - (63-0009) COMBINATION PH SENSOR, SUB. TYPE ..................................................... 21

FIGURE 14 - SEALED FLOWCELL DETAILS ..................................................................................... 22

FIGURE 15 - TWIST-LOCK FLOW TEE ........................................................................................... 23

FIGURE 16 - LOCK-N-LOAD SENSOR EXPLODED VIEW ................................................................... 24

FIGURE 17 – Q46 CONNECTIONS ................................................................................................ 27

FIGURE 18 – Q46 RELAY CONNECTIONS ...................................................................................... 28

FIGURE 19 - OPTIONAL RELAY BOARD WIRING ............................................................................. 29

FIGURE 20 - OPTIONAL ANALOG OUTPUT WIRING ......................................................................... 29

FIGURE 21 - CABLE DESCRIPTION, MODEL Q25P ......................................................................... 30

FIGURE 22 - DETACHABLE SINGLE SHIELDED CABLE, MODEL Q25P .............................................. 31

FIGURE 23 - Q46P SENSOR CONNECTIONS ................................................................................. 32

FIGURE 24 - SENSOR CABLE PREPARATION ................................................................................. 33

FIGURE 25 - JUNCTION BOX INTERCONNECT WIRING .................................................................... 34

FIGURE 26 – OEM SENSOR CONNECTIONS, COMBINATION ELECTRODES ...................................... 35

FIGURE 27 – ATI COMBINATION ELECTRODE CONNECTIONS ......................................................... 36

FIGURE 28 - EXTERNAL PREAMP FOR CONVENTIONAL SENSOR WIRING ......................................... 37

FIGURE 29 - USER INTERFACE ..................................................................................................... 38

FIGURE 30 - SOFTWARE MAP ...................................................................................................... 43

FIGURE 31 - AUTOMATIC PH BUFFER TABLES ............................................................................... 48

FIGURE 32 - AUTOMATIC PH BUFFER TABLES (CONT’D) ................................................................ 49

FIGURE 33 - CONTROL RELAY EXAMPLE, HYSTERESIS AND OPPOSITE PHASE ................................ 56

FIGURE 34 - ALARM RELAY EXAMPLE .......................................................................................... 57

FIGURE 35 - Q45H ISA (IDEAL) PID EQUATION ............................................................................ 71

FIGURE 36 - REPLACING THE SALTBRIDGE AND REFERENCE BUFFER ............................................ 81

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Part 1 - Introduction

1.1 General

The Model Q46P provides continuous measurement of pH in aqueous systems.

It is suitable for potable water, wastewater, and a wide variety of process water

applications. Q46P monitors may be used with Q25P “differential” pH sensors or

a variety of conventional “combination” pH sensors.

Monitors are available in two electronic versions, a universal AC powered

monitor for operation from 90-260 VAC and a 12-24 VDC unit. Both versions

provide two 4-20 mA analog outputs and 3 SPDT relays. One analog output may

be configured for PID control and one of the relays may be configured to provide

a remote trouble indication.

The Q46P is available with a few options to expand the capabilities of the

monitor. Users may select either a third analog 4-20 mA output or an expansion

card that provides three additional low voltage SPST relays. The expansion

relays are not isolated from each other.

This monitor also provides digital communication capability. Users may order

Q46 systems with either Profibus DP, Modbus RTU, or Ethernet communications

boards factory installed.

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1.2 Features

· Standard Q46P Analyzers have fully isolated inputs and outputs. Analog outputs

are additionally completely isolated from each other.

· Available in either 90-260 VAC or 12-24 VDC power supply systems. All features

remain the same in both variations.

· Output Hold, Output Simulate, Output Alarm, and Output Delay Functions. All

forced changes in output condition include bumpless transfer for gradual return to

on-line signal levels to avoid system control shocks on both analog outputs.

· Three 6 amp SPDT relay outputs and two analog 4-20 mA outputs are standard.

Software settings for relay control include setpoint, deadband, phase, delay, and

failsafe. An optional 3-relay card, for 0-30 V signals, is available to bring the total

to 6 relays.

· Selectable PID controller on main analog output. PID controller can operate with

instrument configured as loop-power analyzer or as one of the two outputs on the

AC powered instrument. PID includes manual operation feature, and diagnostic

“stuck-controller” timer feature for alarm output of control problems.

· Digital communication option for Profibus-DP, Modbus-RTU. More versions

pending. See Q46 Digital Communications Manual for Specifications.

· Two analog outputs may be configured to track pH and temperature. Both

analog outputs can be individually programmed to fail to specific values. An

optional third output is available, providing separate outputs for pH or

Temperature.

· Low voltage relay expansion board provides for analyzer control of the optional

“air blast” sensor cleaning system available for submersion applications.

· Sensor diagnostics monitor glass breakage, sensor leaks, and RTD condition.

Diagnostic messages provide a clear description of problems.

· Two-point and sample calibration methods include auto-buffer recognition from

13 built-in buffer tables, with stability checks during calibration.

· Selectable Pt1000 or Pt100 temperature inputs.

· Security lock feature to prevent unauthorized tampering.

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1.3 Q46P System Specifications

Displayed Parameters Main input, 0.00 to 14.00 pH

Sensor temperature, -10.0 to 110.0 °C (14 to 230ºF)

Loop current, 4.00 to 20.00 mA

Sensor slope/offset

Model number and software version

Enclosure NEMA 4X, polycarbonate, stainless steel hardware,

weatherproof and corrosion resistant.

Mounting Options Wall or pipe mount bracket standard. Bracket suitable for

either 1.5” or 2” I.D. U-Bolts for pipe mounting. Panel

mounting bracket optional.

Weight 2 lb. (0.9 kg)

Display 0.75” (19.1 mm) high 4-digit main display with sign

12-digit secondary display, 0.3" (7.6 mm) 5x7 dot matrix.

Integral LED back-light for visibility in the dark.

Keypad 4-key membrane type, polycarbonate

Ambient Temperature Service, -20 to 60 °C (-4 to 140 ºF)

Storage, -30 to 70 °C (-22 to 158 ºF)

Ambient Humidity 0 to 95%, indoor/outdoor use, non-condensing.

Altitude Up to 2000 m (6562 Ft.)

Electrical Certification Ordinary Location, cCSAus (CSA and UL standards - both

approved by CSA), pollution degree 2, installation category 2

EMI/RFI Influence Designed to EN 61326-1

Output Isolation 600 V galvanic isolation

Filter (Damping) Adjustable 0-9.9 minutes damping to 90% step input

change.

Temperature Input Selectable Pt1000 or Pt100 RTD with automatic compensation

Power 90 - 260 VAC, 50-60 Hz, 10 VA max

12-24 VDC, 500 mA max.

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Enclosure NEMA 4X, polycarbonate, stainless steel hardware,

weatherproof and corrosion resistant.

Mounting Options Wall or pipe mount bracket standard. Bracket suitable for

either 1.5” or 2” I.D. U-Bolts for pipe mounting.

Panel mount adapter optional.

Conduit Openings Five ½” NPT openings, Adapter can be removed to

provide a 1” NPT opening in the bottom of the enclosure.

Gland seals provided but not installed.

Relays, Electromechanical: Three SPDT, 6 amp @ 250 VAC, 5 amp @ 24 VDC

contacts. Software selection for setpoint, phase, delay,

deadband, hi-lo alarm, and failsafe.A-B indicators on main

LCD, and C indicator on lower display.

Expansion Relays: Optional relay board with 3 SPST low power relays.

Relays rated 2A @ 30 VDC. Relays are not isolated.

Analog Outputs Two 4-20 mA outputs. Output one programmable for pH or

PID. Output 2 programmable for pH or Temperature. Max

load 500 Ohms for each output. Outputs ground isolated

and isolated from each other. An additional 3rd analog

option is available.

1.4 Q46P Performance Specifications (Common to all variations)

Accuracy 0.1% of span or better (± 0.01 pH)

Repeatability 0.1% of span or better (± 0.01 pH)

Sensitivity 0.05% of span (± 0.01 pH)

Stability 0.05% of span per 24 hours, non-cumulative

Supply Voltage Effects ± 0.05% span

Instrument Response Time 6 seconds to 90% of step input at lowest setting

Temperature Drift Span or zero, 0.02% of span/°C

Max. Sensor-Instrument 3,000 ft. (914 meters) w/ preamp,

Distance 30 ft. (9.1 meters) w/o preamp

Sensor Types Model Q25P pH w/ preamp - 5 wire input, or combination

style pH electrode w/ TC

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1.5 General – Q25P pH Sensor

Model Q25P “differential” pH sensors are the most commonly used sensors with

the Q46P monitor. The differential design utilizes a second glass measuring

electrode contained in an internal buffer as the reference element. This

eliminates the need for a silver/silver chloride reference used in conventional pH

sensor designs. It is designed to perform in the harshest of environments,

including applications that poison conventional pH sensors. All seals are dual

o-ring using multiple sealing materials.

Q25P sensors are available with a choice of two glass types. For the most

demanding industrial applications, P1 glass should be used. This glass is thicker

and will last longer in higher temperature and pressure applications. On the

other hand, P1 glass has a very high impedance and is not suggested for use in

very cold applications. P2 glass is a good general purpose glass that is better for

drinking water, wastewater, and low temperature industrial applications. This

glass is somewhat thinner with lower impendence and can handle cold water

more easily. Note that the salt bridge is different for these two sensors.

1.6 Sensor Features

· A high volume, dual junction saltbridge to maximize the in-service lifetime of

the sensor. The annular junction provides a large surface area to minimize

the chance of fouling. Large electrolyte volume and dual reference junctions

minimize contamination. The saltbridge is replaceable.

· An integral preamplifier encapsulated provides a low impedance signal output

which ensures stable readings in noisy environments. Sensor to transmitter

separation can be up to 3,000 feet (914 meters).

· Pt1000 RTD. The temperature element used in ATI sensors is highly

accurate and provides a highly linear output.

· Available in various configurations including submersible, flow type with quick

disconnect, sanitary, and insertion.

ATI Q46P pH System Part 1 – Introduction

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1.7 Q25P Sensor Specifications

Measuring Range 0 to 14.00 pH

Sensitivity 0.01 pH

Stability 0.02 pH per 24 hours, non-cumulative

Wetted Materials PEEK, ceramic, titanium, glass, Viton, EDPM

(optional: 316 stainless steel body)

Temperature Compensation Pt1000 RTD

Sensor Cable 6 Conductor (5 are used) plus 2 shields,

15 feet (4.6 meters) standard length

Temperature Range -5 to +95 °C (23 to 203 °F)

Pressure Range 0 to 100 psig

Maximum Flow Rate 10 feet (3 meters) per second

Sensor to Analyzer Distance 3,000 feet (914 meters) maximum

Sensor Body Options 1” NPT convertible, 1¼” insertion, 1½” or 2” sanitary-style

Weight 1 lb. (0.45 kg)

Notes: 1. The type of hardware used to mount the sensor may limit the maximum

temperature and pressure ratings. Please consult the hardware

manufacturer’s specifications to obtain the relevant temperature and pressure

rating information.

2. The maximum flow rate specification is lower for process solutions with low

ionic conductivity or high suspended solids concentration. High flow rates in

low ionic conductivity processes may cause a measurement error due to static

electrical discharge. High flow rates in processes with high suspended solids

concentration may decrease the functional life of the sensor by eroding the

pH-sensitive glass electrode.

ATI Q46P pH System Part 1 – Introduction

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1.8 Important Sensor Notes

· The glass electrode must be wetted at all times to ensure proper functionality.

Q25P sensors are shipped with a fluid-filled cap over the electrode to enable

immediate use (remove cap before installing, save for storage and shipping

purposes). Electrodes that have dried out for any reason should be hydrated

for 24 hours to restore full functionality.

· Hydrofluoric acid (HF) will dissolve conventional glass electrodes. For

applications involving hydrofluoric acid, a pH sensor with antimony electrode

is recommended.

NOTE: The standard Q25P process electrode is made of glass and can break if

not handled properly. Should the electrode ever break, USE CAUTION

when handling the sensor to avoid serious cuts.

Equipment bearing this marking may not be discarded by traditional

methods in the European community after August 12 2005 per EU

Directive 2002/96/EC. End users must return old equipment to the

manufacturer for proper disposal.

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Part 2 – Analyzer Mounting

2.1 General

All Q46 Series instruments provide for mounting flexibility. A bracket is included

that allows mounting to walls or pipes. In all cases, choose a location that is

readily accessible for calibrations. Also consider that it may be necessary to

utilize a location where solutions can be used during the calibration process. To

take full advantage of the high contrast display, mount the instrument in a

location where the display can be viewed from various angles and long

distances.

Locate the instrument in close proximity to the point of sensor installation - this

will allow easy access during calibration. The standard cable length of the pH

sensor is 15 feet. For sensor cables longer than 30 feet, use the optional

junction box (07-0100) and sensor interconnect cable (31-0057).

Figure 1 – Q46 Enclosure Dimensions

ATI Q46P pH System Part 2 – Mounting

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2.2 Wall or Pipe Mount

A PVC mounting bracket with attachment screws is supplied with each

transmitter. The multi-purpose bracket is attached to the rear of the enclosure

using the four flat head screws. The instrument is then attached to the wall using

the four outer mounting holes in the bracket. These holes are slotted to

accommodate two sizes of u-bolt that may be used to pipe mount the unit. Slots

will accommodate u-bolts designed for 1½ “or 2” pipe. The actual center to

center dimensions for the u-bolts are shown in the drawing. Note that these slots

are for u-bolts with ¼-20 threads. The 1½” pipe u-bolt (2” I.D. clearance) is

available from ATI in type 304 stainless steel under part number (47-0005).

Figure 2 - Wall or Pipe Mounting Bracket

ATI Q46P pH System Part 2 – Mounting

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Figure 3 - Wall Mounting Diagram

Figure 4 - Pipe Mounting Diagram

Note: Analyzer shown with optional

Profibus Connector mounted to

side of enclosure.

ATI Q46P pH System Part 2 – Mounting

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2.3 Panel Mounting

Panel mounting uses the panel mounting flange molded into the rear section of

the enclosure. Figure 5 provides dimensions for the panel cutout required for

mounting.

The panel mounting bracket kit must be ordered separately (part number 05-

0094). This kit contains a metal retainer bracket that attaches to the rear of the

enclosure, 4 screws for attachment of this bracket, and a sealing gasket to insure

that the panel mounted monitor provides a water tight seal when mounted to a

panel.

The sealing gasket must first be attached to the enclosure. The gasket contains

an adhesive on one side so that it remains in place on the enclosure. Remove

the protective paper from the adhesive side of the gasket and slide the gasket

over the back of the enclosure so that the adhesive side lines up with the back of

the enclosure flange. Once in place, you can proceed to mount the monitor in

the panel.

Figure 5 - 115/230 VAC Panel Mount & Cut-out

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Part 3 – Sensor/Flowcell Mounting

3.1 General

The Q25P pH Sensor mounting options include flow-through, submersion,

insertion (special hardware required), or sanitary mount depending on the type of

sensor purchased.

Q25P Differential pH Sensors are available in 4 different versions as shown in

Figure 6. The convertible style is the most common and can be used for either

flow-through or submersion applications. A convertible sensor with a quick-

disconnect receptacle is available. This version may not be submerged and

should not be used in unprotected outdoor locations. For special applications,

the Q25P is also available in a stainless steel bodied version for insertion type

installations, or can be supplied in either 1.5” or 2” sanitary versions.

Figure 6 - Q25 Sensor Types

ATI Q46P pH System Part 3 – Sensor/Flowcell Mounting

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3.2 Flow Tee Mounting

Convertible sensors may be used in a 1” flow tee as shown in Figure 7. The flow

tee is a modified pipe fitting that accommodates the pipe thread on the front of

the sensor. Sample must flow directly against the face of the sensor as shown.

The sensor may be mounted horizontally provided that the outlet flow is pointed

up to avoid “air locking” in the tee. Note that standard 1” tee fittings will not work

without modification due to clearance problems in most molded tees.

Figure 7 - Flow Through Tee Mount

ATI Q46P pH System Part 3 – Sensor/Flowcell Mounting

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3.3 Union Mounting

For mounting the sensor in larger pipe and allowing for easy sensor removal, a 1

½” or 2” union mount adapter system is available. This arrangement allows

connection of the sensor to pipe sizes up to 2 inches (using adapters if

necessary) while allowing easy removal without twisting sensor wires. Contact

ATI for part numbers and prices for union mount assemblies and associated pipe

tees. The 1 ½” assembly is shown below. The 2” tee assembly is similar.

Figure 8 - 1.5" Union Mount

Q45P

SENSOR

1½ UNION

1½ NIPPLE

1 ½ TEE

(CUSTOMER

SUPPLIED)

1½ UNIO

N

1½ NIPPLE

1 ½ TEE

(CUSTOMER

SUPPLIED)

ATI Q46P pH System Part 3 – Sensor/Flowcell Mounting

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3.4 Submersion Mounting

When using this sensor for submersion applications, mount the sensor to the end

of a 1” mounting pipe using a 1” coupling. ATI’s (00-0628) mounting assembly

shown in Figure 9 is available for submersible applications. This assembly is

designed to mount to standard handrails and facilitates insertion and removal of

the sensor.

Figure 9 - Sensor Submersion Mount

ATI Q46P pH System Part 3 – Sensor/Flowcell Mounting

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3.5 Insertion Mounting

Special insertion mounting hardware is available for applications requiring the

removal of the sensor from a process line or tank without shutting off the sample

flow in the line. Figure 10 & Figure 11 show typical insertion assemblies.

Figure 10 - S.S. Sensor Insertion Mount

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Analytical Technology Q46P User manual

Analytical Technology Q46P User manual

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